Abstract
With the development of new alloys and composites, existing drilling techniques have technical constraints for machining difficult-to-cut materials. To overcome these constraints, researchers have developed various drilling methods, including ultrasonic-assisted drilling (UAD). An ultrasonic spindle with a 30 kHz resonant frequency was designed to apply UAD to hole processing. The resonance frequency and vibration mode were predicted using the finite element method (FEM), and a vibration nodal plane was selected. The resonance frequency and impedance characteristics of the ultrasonic spindle were determined using an impedance analyzer, and an error of approximately 1.9% was predicted using the FEM. Next, the vibration characteristics of the ultrasonic spindle were analyzed using a laser displacement system. The vibration displacement tests showed amplitudes of 39.7 and 0.5 μm at the end of the drilling tool and the nodal plane, respectively. The design validity of the manufactured ultrasonic spindle was demonstrated based on experimental drilling results.
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